Airfoil Tip Coating Inspection With Optical Coverage Scanning

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Conventional visual inspection methods for airfoil tips in gas turbine engines are time-consuming and provide inconsistent criteria for determining coating acceptability, leading to potential inefficiencies in maintenance and overhaul processes.

Innovation Solution

Implementing an optical scanner and micro computed tomography scanner to assess the coating coverage on airfoil tips, using parameters like protrusion density and surface roughness, and a machine learning system to refine inspection criteria.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If visual inspection methods are used to assess coating coverage on airfoil tips, then the inspection process is simple and quick, but the measurement precision and consistency of evaluation criteria are insufficient

Engineering Contradiction:

Improvecoating coverage assessment accuracyVSAvoidinspection system complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent replaces manual visual inspection with an optical scanning system that captures images of airfoil tips and uses image processing algorithms to automatically measure coating coverage. This substitution of mechanical/manual inspection with optical and computational methods directly resolves the contradiction by providing precise, consistent measurements without requiring complex physical contact probes or tactile measurement devices.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent creates a digital copy (image) of the airfoil tip coating and performs measurements on this copy through image processing. This allows precise measurement of coating coverage, protrusion density, and surface characteristics without physically touching or disturbing the actual coating, thereby achieving high measurement precision while keeping the inspection system relatively simple and non-invasive.

Inventive Principle:

Principle #26Copying

2Productivity

If manual visual inspection is performed on all airfoil tips, then the inspection can be completed quickly, but the productivity and thoroughness of coating assessment are reduced

Engineering Contradiction:

Improveinspection throughputVSAvoidcoating assessment accuracy

Core Design Contradiction:

ProductivityVSMeasurement precision

Solution Approach 1:

The optical scanning system enables continuous automated inspection of multiple airfoil tips without the interruptions, repositioning, and subjective judgment delays inherent in manual inspection. The system can rapidly capture and process images of numerous airfoils in sequence, maintaining continuous measurement and assessment operations, thereby simultaneously improving productivity and measurement precision through automated, consistent evaluation of coating coverage and characteristics.

Inventive Principle:

Principle #20Continuity of useful action

3Measurement precision

If comprehensive scanning of all airfoil tips is performed, then the measurement precision and data quality are improved, but the loss of time and inspection duration increase

Engineering Contradiction:

Improvecoating coverage data accuracyVSAvoidinspection time

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

The system performs comprehensive scanning of all airfoil tips to ensure complete data collection and high measurement precision, capturing images and measuring coating parameters for every airfoil in the assembly. This exhaustive approach guarantees thorough assessment and accurate identification of coating deficiencies across the entire rotor, accepting the time investment as necessary for maintaining high productivity through automated processing and preventing future failures.

Inventive Principle:

Principle #16Partial or excessive action

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Enhances the accuracy and efficiency of coating assessment, reducing unnecessary replacements and optimizing maintenance intervals by providing consistent and precise evaluation of coating coverage.

Implementation Method 1

scanning a tip of an airfoil of a bladed rotor with an optical scanner

Methodology Applied

Scientific EffectOptical scanning: Light

Implementation Method 2

scanning, via a micro computed tomography scanner, an area of interest

Methodology Applied

Scientific EffectComputed tomography: Tomography

Data Source

PatentUS12442634B2Visual and/or dimensional tip inspection systems and methods

Publication Date: 2025.10.14 RTX CORP

AI summary

A method can comprise: scanning, via an optical scanner, a tip of an airfoil of a bladed rotor, the tip including a coating disposed thereon, the coating comprising a metal plating and a plurality of protrusions, each protrusion in the plurality of protrusions extending from the metal plating; comparing a coating parameter of the coating to a coating parameter threshold based on scanner data from the optical scanner; and determining whether the coating maintains sufficient coverage of the tip of the airfoil based on the comparing.